Bed foundation and mattress assembly

ABSTRACT

AN IMPROVED BED FOUNDATION AND MATTRESS ASSEMBLY WHICH PROVIDES VARYING DEGREES OF FIRMNESS FOR SUPPORT AND COMFORT OF A HUMAN ANATOMY. THE CENTER SECTION OF THE ASSEMBLY IS STIFFENED TO PROVIDE ADDITIONAL FIRMNESS.

H. J. ROBINS BED FOUNDATION AND MATTRESS ASSEMBLY Dec. 14, 1971 2Sheets-Sheet 1 Filed Sept. 25, 1970 HARRY iggl/Ns BY fam@ A GRA/EYB Dec.14, 1971 H. J. RoBlNs 3,626,523

BED FOUNDATION AND MATTRESS ASSEMBLY Filed Sept. 25, 1970 2 Sheets-Sheetz v Y /4 END PORT/0N INTERMEDIATE PORT/0N EAI/9 PORT/0N HARRY J. Ro/Ns lN VEN 0R.

United States Patent O U.S. Cl. -345 6 Claims ABSTRACT OF THE DISCLOSUREAn improved -bed foundation and mattress assembly which provides varyingdegrees of firmness for support and comfort of a human anatomy. Thecenter section of the assembly is stiffened to provide additionalfirmness.

BACKGROUND AND OBJECTS As is well-known, individual preferences in thefirmness of beds vary widely. A substantial num-ber of people prefer abed which firmly supports their buttocks and the middle portion of theiranatomy. Generally included within such class of people are thosepersons who suffer from back ailments and disorders. Such persons arecontinually searching for a bed which will provide adequate support forthe middle portions of their anatomy without being so rigid in respectto other parts of their anatomy that comfortable sleep is prevented.

It is an object of the invention to provide a bed foundation andmattress assembly which supply support to the human anatomy by varyingthe firmness of such assembly, whereby extra firmness supports themiddle portion of the human anatomy but not the head and feet of suchanatomy.

Another object of the invention is to provide a bed foundation andmattress assembly in which the mattress supplements the bed foundationin supplying varying degrees of firmness to the human anatomy.

It is an object of this invention that such variation in firmness in thebed foundation and mattress assembly will produce no physical distortionin such assembly.

The present invention provides an improved bed foundation and mattressassembly wherein that portion of the bed assembly which supports themiddle portion of a human anatomy has increased firmness. Such improvedbed assembly is comprised of an improved foundation unit and an improvedmattress. The improved bed foundation unit utilizes springs to produceits desired resilient effect. Those springscomprising the intermediateportion of such bed foundation are compressed and prestressed in orderto provide firmer support than provided by the springs comprising theend portions of such foundation unit. The improved mattress coacts withsuch bed foundation; its novel construction supplements the function ofthe bed foundation in providing varying support for the human anatomy.'Ihe improved mattress includes means which correspond with the firmerportion of the bed foundation unit and provide additional support to thehuman anatomy, means which correspond with the firmer portion of the bedfoundation unit and add additional cushioning, and means extendedlongitudinally along the entire length of the mattress which function tointegrate the varying degrees of firmness.

BRIEF DESCRIPTION OF THE DRAWINGS These and other objects, as Well asthe invention itself both as to organization and methods of operation,will become readily apparent in the following description when read inconnection with the accompanying drawings, in which:

FIG. 1 is an exploded view in cross-section of the improved bedfoundation in its prestressed state in cor- "ice respondence with theimproved mattress (the exploded elevation of the mattress is not toscale);

FIG. 2 is a plan view of the improved bed foundation showing the springsattached to the base;

FIG. 3 is a side elevation of FIG. 2 before the springs in theintermediate portion of such -bed foundation have been compressed andprestressed;

FIG. 4 is a side elevation of FIG. 2 after the springs in intermediateportion of such foundation have been compressed and prestressed;

FIG. 5 is an isometric view of a spring utilized in the end portions ofthe bed foundation;

FIG. 6 is an isometric view of a spring utilized in the intermediateportion of the bed foundation (such spring is in its compressed `andprestressed state); and

FIG. 7 is a plan view of the mattress with the outer covering partiallycut away showing the flexible stiffening means, the flexible cushionmeans, and the integrating means.

DESCRIPTION OF THE PREFERRED EMBODIMENT The improved bed foundation andmattress assembly according to the invention functions to provide firmsupport to the middle portion of the anatomy of a person without beingso rigid in respect to other parts of a persons anatomy that comfortablesleep is prevented. Such improved assembly is a combination of afoundation unit and a mattress; the latter supplements the former.

Referring to the drawings, FIG. 1 illustrates the improved assemblycomprising a foundation unit indicated generally at 10, whichcorresponds generally to a conventional box-spring, and a mattressindicated generally at 12, which corresponds generally to a conventionalmattress.

Foundation unit 10 functions to provide a sturdy -base for the bedassembly, and provides the primary support to the human anatomy. In thisregard, foundation unit 10 functions to provide the primary means ofvarying the firmness of the support provided to the human anatomy.Foundation unit 10 includes a solidly constructed base comprising aplurality of members 14 extending longitudinally along the length of theentire bed assembly to which are secured a plurality of cross-members16. Such base may be constructed in any desired form so long as itprovides the sturdy support needed for the vremaining elements of thebed assembly.

The springs included within such foundation unit 10 function to providethe varying degrees of rmness desired of such foundation unit 10. Inorder to provide firmer support for the buttocks and middle portion ofthe human anatomy than for the head and feet of such anatomy, thesupport provided -by such springs will vary depending on whether theyare positioned in the intermediate portion or the end portions of suchfoundation unit 10.

FIGS. 1 and 2 illustrate that a plurality of springs are attached to theplurality of cross-members 16. Such springs are of two types. The firsttype of spring 18 is constructed in upstanding coil from a desired metalof a desired gauge and with a desired number of coils per inch. Thesecond type of spring 20 is also constructed in upstanding coiled form.However, such second spring 20 is preferably constructed so that in itsuncompressed state each spring has a greater height than such firstspring 18. In the preferred embodiment of the invention, such secondspring 20 is constructed from the same metal utilized in the firstspring 18, but such metal is of a heavier gauge than that used toconstruct the first spring 18. Additionally, the length of the piece ofmetal used to construct the second spring 20 is longer than that used toconstruct the first spring 18. The'use of a longer strip of metal toconstruct the second spring 20 allows production of such second springwith a higher height than such first spring 18 even though the desirednumber of coils per inch remains constant.

The springs in a bed foundation unit function to exert pressure in anupward direction on the human anatomy and thereby support such body.Nevertheless, such springs yield somewhat to such body and thereby allowcomfortable sleep. Springs in a bed assembly are a compromise between ameans which supplies maximum support without yielding, such as concreteslab, and a means which completely yields and provides almost nosupport, such as a deep feather bed. In the bed foundation and mattressassembly according to this invention, such second springs 20 aredesigned so that when they are compressed and prestressed, they storemore potential energy than the first springs 18 and thereby exert moreupward force upon the body. Thus, such second springs 20 provides thedesired additional support for the intermediate portions of the humananatomy but still yield somewhat to the motions of such body and thuspermit comfortable sleep.

Referring to FIGS. and 6 which are isometric drawings of a first spring18 and a second spring 20 respectively, it is observed that in thepreferred embodiment of this invention such springs are suitably securedat their lower ends to the cross-members 16. Such first and secondsprings 18 and 20 may be secured to the cross-members 16 through the useof wire means 28 extending transversely and longitudinally along thebase of the bed foundation unit. Such wire means 28 physicallyinterconnect with the lower coils of such first and second springs 18and 20 and when secured by a means 32, such as a staple, to thecross-member 16, act to secure the individual springs to suchcross-members 16. As previously indicated, in the preferred embodimentof this invention a plurality of such first springs 18 are secured tothe cross-members comprising the end portions of the bed assembly. Aplurality of such second springs 2f) are secured to the cross-memberscomprising the intermediate portion of such bed assembly.

When the first and second springs 18 and 20 have been secured to thecross-members 16 of the foundation unit 10, variations in the heightbetween such two types of springs are readily apparent. Referring toFIG. 3, it is observed that the plurality of second springs 20comprising the intermediate portion of the foundation unit are of agreater height than the plurality of first springs 18 comprising the endportions of such foundation. As previously indicated, increased supportwill be afforded the intermediate portion of the human anatomy if suchsecond springs 20 are compressed and prestressed. Therefore, a strappingmeans 34 functions to compress and prestress each of the plurality ofsecond springs 20. In the preferred embodiment of this invention, thestrapping means 34- is constructed of an inexpensive, easily obtainablematerial such as leather or plastic. Each strap is of a desired lengthso that when each second spring is secured, its compressed height willequal that of the first springs 18.

A preferred method of securing such strap to such springs is illustratedin FIGS. 3 and 4. Each strap is looped beneath the proper cross-member16 and on either side of the second spring 20. Suitably connected toeach end of such strap 34 is a conventional means 36, such as a braddedhook, for connecting each end of such strap to the upper coil of suchsecond spring 20.

Once the plurality of second springs 20 have been compressed andprestressed so that all springs 18 and 20 are at approximately the sameheight, it is desired that the upper ends of such springs be secured ina fixed relationship to each other. The method of securing such springsutilized in the preferred embodiment of this invention includes aplurality of wire means extending transversely and longitudinally acrossthe tops of the rst and second springs 18 and 20. Referring to FIGS. 2,5 and 6, each length of such wire means 38 contains a plurality ofcrimps therein. rl`he crimps are spaced so that each crimp communicateswith the inside top coil of a spring. A plurality of connecting wires 40are utilized to secure such transverse and longitudinal wire means tothe top coil of such first and second springs. Each connecting wire 40slips under the top coil of a spring and over the transversing orlongitudinal wire which is perpendicular to such connecting wire and istangent to the top coil of such spring at that point.

When the plurality of first and second springs 18 and 20 have beensecured in their desired fixed relationship, the outer covering 42 isutilized to completely enclose the top and sides of such plurality ofsprings. FIG. l illustrates that such outer covering is secured to thebase. The outer covering 42 may be constructed of any of a number ofmaterials such as cotton cloth.

An improved bed foundation unit which supplies the primary support withvarying degrees of firmness for the human anatomy has been disclosed.However, the bed foundation and mattress assembly according to thisinvention utilizes an improved mattress in combination with such bedfoundation unit. Such improved mattress functions to augment andsupplement the varying degrees of firmness utilized to support the humananatomy.

The bulk of the improved mattress is provided by its core 48 whichfunctions to produce the primary cushioning resiliency of the mattress.As illustrated in FIG. 1, the core 48 of the improved mattress 12corresponds to cores used in conventional mattresses, that is, such core48 may be comprised of innersprings, cotton padding, foam rubber, or anyof a number of materials, or any combination thereof. The preferredembodiment of the invention illustrated in FIG. 1 has a mattress corecomprising inner springs 52 and padding 51. In addition to suchconventional core 48, the improved mattress 12 according to thisinvention includes certain components which function to correspond tothe novel aspects of the bed foundation unit 10. Such mattress 12includes a flexible stiffening means 44, a flexible cushioning means 46,and an integrating means 50.

The flexible stiffening means 44 function to correspond with theintermediate firmer portion of the bed foundation unit and provideadditional rigidity and support to the human anatomy in the longitudinaldirection. Referring to FIG. 7, it is illustrated that in the preferredembodiment of the invention these means 44 are conventional devices,such as wires of small diameter, which are secured to each other by aplurality of fiexible cords 45. The plurality of stiffening wires 44extend in a longitudinal direction along the mattress but only over thatintermediate portion of the mattress which corresponds with theintermediate portion of the fundation unit 10. The plurality of suchflexible cords 45 connecting the stiffening wires 44 extend transverselyacross the bed. Thus, although the stiffening wires give support to themiddle portion of the human anatomy in a longitudinal direction, thewires are flexible in transverse direction to allow such wires 44 tomove freely responsive to the transverse contours of the body.

The fiexible cushioning means 46 is a conventional device whichfunctions to cushion and integrate any rapid and discreet variations offirmness which might be produced by the fiexible stiffening means 44.Such fiexible stiffening means 46 is inserted into the improved mattressonly on that portion thereof which corresponds to the intermediateportion of the bed foundation unit 10, which of course causes such meansto correspond with the flexible stiffening means 44. The flexiblecushioning means 46 is a conventional material such as sisal.

The integrating means 50 are included within the improved mattress andfunction to integrate the changes in degress of firmness which might beproduced between the intermediate portion and the end portions of thebed foundation and mattress assembly. The preferred embodiment of theinvention illustrated in FIG. 7 uses conventional devices, such aswires, for such integration means 50. Such wires extend longitudinallyalong the entire length of the mattress and correspond to both theintermediate portion and end portions of the bed foundation unit. As inthe case of the flexible stilfening means 44, some conventional means(not shown) must be employed to secure such wires 50 in a fixedtransverse relationship to each other. As will be discussed below, thepreferred embodiment of this invention juxtapositions such wires 50 withthe inner springs 52. Accordingly, such wires 50 may be secured to suchinner springs 52 to effect the desired fixed relationship.

Although the flexible stiffening means 46', the flexible cushioningmeans 50 and the integrating means 50 may be positioned at anyhorizontal stratum inside the mattress, FIG. 1 illustrates thepositioning of such means in the preferred embodiment of this invention.it has been previously stated that the core 48 of the improved mattress12 is a combination of inner springs 52 and cotton padding 51. Formaximum comfort in such a preferred embodiment, the flexible stiffeningmeans 44 are positioned on top of the outer covering 54 on the lowerside of the mattress. The tiexible cushioning means 46 are thenpositioned on top of the flexible stiffening means 44 to integrate theeffect of such fiexible stiffening means. On top of such flexiblecushioning means 46 is inserted a layer of cotton padding 51. Theintegrating means `50 comprised of a plurality of wires are placed ontop of such cotton padding 51 and such wires 50 are secured to the innersprings 52. Another layer of cotton padding 51 is secured to the top ofinner springs 52, and an outer covering 54 of cotton cloth or the likeis utilized to completely inclose the components comprising suchmattress. Conventional means, such as staples or cord, is utilized tosecure all of the components in the improved mattress in a desired fixedrelationship.

In accordance with the present invention, it has been determined thatthe greatest support and sensitivity forl the entire human anatomy isobtained through the apparatus disclosed herein. It has been found thatthe mere use of the improved bed foundation unit with a conventionalmattress is not satisfactory. Rather, the improved mattress, asdisclosed herein, is necessary to provide the desired support withoutthe inordinate rigidity which prevents comfortable sleep. It has alsobeen found that the use of compressed and prestressed coils in theintermediate portion of the mattress did not function as well as thepresent invention which employs compressed and prestressed coils in theintermediate portion of the bed foundation unit. It has been determinedthat the use of the same gauge wire in both the first and second springsdid not provide the support and sensitivity provided in the presentinvention, even if such second springs constructed of the same gaugewire as such first springs were compressed and prestressed in the mannerof this invention. Conversely, it has been determined that the use of aheavier gauge -wire in the construction of the second spring (comprisingthe intermediate portion of such foundation unit) without compressingand prestressing such springs did not produce the support andsensitivity found in the present invention.

The invention has been particularly shown and defined with reference toa preferred embodiment. However, many variations and modifications ofthe invention will now be apparent to those having skill in the art. Forinstance, a plurality of methods may be utilized to secure the firstsprings and second springs to the base. Different methods may beutilized to secure the tops of such first and second springs to eachother in a desired relationship. A plurality of types of material may beutilized as the flexible stiffening means, the flexible cushioning means7 and the integrating means. Nevertheless, the substitution of theseequivalents for each means are within the teachings of this invention.

The foregoing disclosure and description of the invention areillustrative and explanatory thereof and various changes in the size,shape and materials, as well as in the details of the illustratedconstruction, may be made within the scope of the appended claimswithout departing from the spirit of the invention.

What I claim is:

1. A bed foundation and mattress assembly comprising:

(a) foundation means including,

a base means,

a plurality of first springs of substantially equal height,

a plurality of second springs of greater unstressed height than suchfirst springs,

means to secure one end of each of such first and second springs to suchbase in a desired fixed relationship wherein such first springs arepositioned at the end portions of such base and such second springs arepositioned at the intermediate portion of such base,

means to compress and prestress such second springs so that the heightof each is equal to the height of such first springs,

means to secure the other ends of each of such first springs and suchcompressed second springs to each other in a desired fixed relationship,and

a cover means which encloses the top and sides of such assembled springsand attaches to said base;

mattress means including:

a core means extending longitudinally along the entire length of themattress providing the primary cushioning resiliency,

fiexible stiffening means which positionally correspond with said secondsprings in said bed foundation and which supplement the firm support ofsuch second springs,

flexible cushioning means which positionally correspond With said secondsprings in said bed foundation and said fiexible stiffening means, whichcushion and integrate the effect of such flexible stiffening means,

integrating means extending longitudinally along the entire length ofthe mattress core which dampen the rate of change of firmness betweensuch intermediate portion and such end portions of the bed foundationand mattress of such assembly and also supplement the support affordedthe human anatomy,

means to secure such core, such -fiexible stiffening means, suchfiexible cushioning means, and such integrating means in a desired fixedrelationship, and

a cover means which encloses such core, flexible stiffening means,flexible cushioning means and integrating means.

2 A bed foundation and mattress assembly according to claim 1 whereinsuch first and second springs are constructed from helically coiledwire, and the length of wire utilized to construct each such secondspring is a heavier gauge and of a longer length than the length of wireutilized to construct each such first spring.

3. A bed foundation and mattress assembly according to claim 1 whereinthe means to compress and prestress such second springs includes:

a strapping means of desired length which, when secured to such base andsecured to the top coil of such second spring, will reduce the height ofeach such second spring so that it corresponds to the height of eachsuch first spring, and

means connected to each end of such strapping means to connect each endof such strapping means to the top coil of each such second spring.

4. A bed foundation and mattress assembly according to claim 1 whereinsuch stiffening means included within such mattress is constructed of aplurality of wires of small diameter extending longitudinally along thelength of such assembly, and which are connected to a plurality ofexible means extending transversely across such assembly.

5. A bed foundation and mattress assembly according to claim 1 whereinthe exible cushioning means included within such mattress is constructedof sisal.

6. A bed foundation and mattress assembly according to claim 1 whereinthe integrating means in such mattress is constructed of a plurality ofwires of small diameter which extend longitudinally along the entirelength of such mattress and diminish the varying degrees of rmnessexisting between the intermediate portion of such assembly and the endportions of such assembly.

References Cited CASMIR A. NUNBERG, Primary Examiner 10 A. CALVERT,Assistant Examiner U.S. Cl. X.R.

